Method and system for operating a racking system preferably in a dispatch unit

ABSTRACT

A method for operating a rack system preferably in a dispatch unit ( 1 ), with a rack ( 2 ) and an associated rack serving device for the storage and retrieval of containers ( 3 ), trays or the like to or from the rack. A rack region of the rack ( 2 ) has a plurality of rack planes ( 13 ) arranged one above the other and is served by a dedicated, mechanically coupled, height and length-adjustable rack serving device ( 4 ). In each track region embodied as an independent, closed rack unit (A, B, C), containers ( 3 ), trays or the like undergo interim storage in a buffer zone (P 1 , P 2 , P 3 ) on the same level, are transferred for storage or retrieval and transported by an elevator ( 5; 6   a   , 6   b ) and/or a preferably horizontal transport connection (F 1 , F 2 ) arranged in the region of the rack unit (A, B, C) at the same level, from or to a transport system or workplace outside the rack system.

FIELD OF THE INVENTION

The present invention pertains to a method and a system for operating arack system preferably in a dispatch unit, with a rack and an associatedrack serving device for the storage and retrieval of containers, traysor the like into or out of the rack.

Whenever the term “container” is used below it shall not be defined in alimiting manner; the present invention rather also comprises systems inwhich other transport units, e.g., trays or pallets are used to storeand transport the product to be dispatched.

BACKGROUND OF THE INVENTION

According to a known prior art, containers are removed from a containerstorage area and sent via a height-adjustable rack serving device, whichcan be displaced along the container storage area, to a centraldistribution system, which joins the container storage area. Inparticular, the rack serving device serves two opposite storage racksover the entire height of the rack (cf. DE 197 12 839 A1). The limiteddispatch output and inflexibility of the rack serving system is adisadvantage.

SUMMARY OF THE INVENTION

The object of the present invention is essentially to make the prior-artmethod and system more efficient and to correspondingly make availablewith simple means an efficient method and an efficient serving systemfor operating a rack system preferably in a dispatch unit.

The essence of the method according to the present invention is that arack region of the rack system, which rack region comprises a pluralityof rack planes arranged one above the other, is served by a dedicated,mechanically coupled, height- and length-adjustable rack serving device,and that containers, trays or the like, which are taken over by the rackserving device for storage or released for retrieval and are transportedby means of at least one elevator and/or a transport connection from orto a transport system or workplace located outside the rack system, arestored on an interim basis in a buffer zone located on the same level asan interface to the outside in each rack region embodied as anindependent and closed rack unit.

The containers are preferably transported via the horizontal transportconnection arranged on the same level in the region of the rack unitwithout crossing to or from an individual workplace, especially to orfrom an individual dispatch place of a dispatch unit, preferably on aclosed path, in a so-called “loop.”

Consequently, the rack in a rack serving system according to the presentinvention is divided into at least two rack regions arranged one abovethe other, which comprise a plurality of adjacent rack planes arrangedone above the other each, wherein each rack region has as an independentand closed rack unit a dedicated, mechanically coupled, height-andlength-adjustable rack serving device. Each rack serving devicepreferably covers a working range of about 4 m of rack height. Each rackregion comprises, in particular, a transfer station, which is a rigidpart of the rack and is located on the same level, with a buffer zone asan interface to the outside and, furthermore, at least one elevator,which joins the buffer zones and is preferably a rigid part of the rack,and/or a transport connection, which is connected to each buffer zoneand is preferably a rigid part of the rack in the rack region, forfeeding or removing containers, trays or the like to or from a transportsystem or workplace located outside the rack system, preferably withoutcrossing, to and from an individual dispatch place of a dispatch unit(“product-to-man system”). A plurality of containers, usually containersor boxes, can be picked up and deposited from the vehicle or rackserving device in the buffer zone. The buffer zone stores the productsuntil they can be taken over by the elevator system. The individual,independent and closed planes or rack units and the materials handlingtechnology located outside the rack system are linked with one anotherby an elevator or with a transport connection. As a result, a highlyflexible interface can be created with the materials handling technologylocated outside the rack system and, in particular, a high dispatchcapacity can be set up.

Advantages of the system according to the present invention over theprior-art system:

As many planes or rack units as desired can be arranged one aboveanother. Rack heights of 20 m or higher can be attained in a simplemanner. The height of the overall system is limited only by thestability of the rack system and the elevator mast.

The throughput of the system is higher than in prior-art systems withonly one vehicle or rack serving device for the overall height of therack system (as for instance 3,661,280-Atwater). The throughput isdetermined, besides by the number of rack serving devices, essentiallyby the elevator system or the transport system used for the connection,which links the individual rack serving devices with the materialshandling technology located outside the rack system.

Each plane or rack unit of the rack system is accessible by means of aladder. Each rack unit is enclosed in itself. Service and repairoperations can thus be performed on each rack unit separately, withouthaving to put the entire system out of operation. This is an essentialadvantage compared with the prior-art rack serving device. The safety ofthe overall system against failure is thus increased in the longer term.

The individual vehicles or height-adjustable rack serving devices, whichare longitudinally displaceable at a rack front, are built up such thatthe mast is arranged centrally at the elevating chassis. As a result,the actions of forces due to the acceleration and braking of the vehicleor elevating platform can be minimized, and a lightweight design can beoptimally implemented.

By using an elevator system as a link between the individual planes orrack units and the materials handling technology located outside therack system, it is possible to serve a larger number of transfer pointsand buffer zones of the rack serving vehicles in a simple and effectivemanner. If a separate elevator is used for the storage and retrieval ofproducts, high throughputs are possible even in the case of a smallstorage area.

Another advantage is that the vehicles or rack serving devices arecompatible, and a rack serving device can be replaced with a new ordifferent, existing rack serving device in a simple manner.

It is possible to serve two planes or two rack units of the rack systemwith a feeding and removing materials handling technology. Thedifference in height is achieved by an elevating or lowering movement.

Each plane or each rack unit has an independent, enclosed functionalarea. As a result, separate interfaces of the materials handlingtechnology can be served as a dedicated overall system. This propertycan also be utilized in separate planes as a “product-to-man system.”This means that a plurality of independent rack serving systems functionin a single mechanical rack system. Optimal use over a plurality ofplanes of a building is possible as a result.

Each plane or each rack unit can be operated as a “stand-alone solution”in respect to the electronic control means. However, it is also possibleto integrate a plurality of systems in one control.

The entire rack system can be optimally used for different types ofcontainers. This means that, e.g., boxes can be dynamically stored andmanaged in one plane region, but normal containers are stored andmanaged in another plane system. Furthermore, the planes or rack unitsmay also differ in the number of storage depths. This means that oneplane or rack unit is used for two-deep storage, and the other plane orrack unit is used for single-depth or four-deep storage. The greatadvantage is the optimal utilization of the rack system and thesimplicity of the load-carrying means used. The load-carrying means canbe optimally adapted to the requirements. It is also possible, e.g., toarrange special storage means such as flow racks in each plane or rackunit and to serve them with load-carrying means specially designed forthem.

The rack serving device system is integrated within the rack. The rackaccommodates the guiding system for the vehicle system and is thusconsidered to be an integrated system.

Due to the low overall height of the vehicle system, the overall systemis very service-friendly, because the individual planes or rack unitscan all be reached in a simple manner.

If a plurality of plane systems serve one plane system or if a pluralityof plane systems are integrated in a single plane system, the throughputis guaranteed by corresponding buffer systems and connection systems.

The various features of novelty which characterize the invention arepointed out with particularity in the claims annexed to and forming apart of this disclosure. For a better understanding of the invention,its operating advantages and specific objects attained by its uses,reference is made to the accompanying drawings and descriptive matter inwhich preferred embodiments of the invention are illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of a rack serving systemaccording to the present invention of a dispatch unit, with a compositerack comprising three double racks and three rack serving devices atdifferent heights of the rack;

FIG. 2 is an enlarged detail of the rack serving system according toFIG. 1;

FIG. 3 is a schematic side view of the rack serving system according toFIG. 1;

FIG. 4 is a schematic top view of the rack serving system according toFIG. 1;

FIG. 5 is a schematic side view of the rack serving device according toFIGS. 1 through 4;

FIG. 6 is a schematic top view of the rack serving device according toFIGS. 1 through 4;

FIG. 7 is a schematic perspective view of another embodiment variant ofa rack serving system according to the present invention of a dispatchunit corresponding to FIGS. 1 through 4;

FIG. 8 is an enlarged detail of the rack serving system according toFIG. 7;

FIG. 9 is a schematic side view of the rack serving system according toFIG. 7; and

FIG. 10 is a schematic top view of the rack serving system according toFIG. 7.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings in particular, according to the drawings, thecontainer storage area of a dispatch unit 1 comprises a composite rack 2comprising three double racks in a parallel arrangement withlongitudinally displaceable rack serving devices 4 according to FIGS. 5and 6, which are arranged in the rack aisles 14.

As can be best recognized from FIGS. 3, 4 as well as 9 and 10, adedicated rack serving device 4 is associated with each rack aisle 14.The overall height of the rack is divided into three rack regions, whichare arranged one above the other and comprise eight rack planes 13arranged one above the other each, wherein each rack region has adedicated, mechanically coupled, height-and length-adjustable rackserving device 4 as an independent and closed rack unit A, B and C.

The rack serving device 4 has an elevating chassis 10 and an elevatingplatform 11 of a small overall height essentially at the same height,the elevating chassis 10 and the elevating platform 11 being arranged onopposite sides of a longitudinally displaceable, driven elevator mast12. The elevator mast 12 extends over the height of each rack unit A, Cand C and is guided at least at its longer longitudinal end in alongitudinal guide rail, which is an integral part of the rack 2.

Each rack region or each rack unit A, B, C has a transfer station whichis a rigid part of the rack and is located on the same level with abuffer zone P1, P2 and P3, respectively, for containers 3, in which saidbuffer zone containers are taken over by the rack serving device 4 forstorage or are released for retrieval, and, furthermore, elevators 6 a,6 b, which are rigid parts of the rack and are connected to the bufferstations in the first embodiment variant according to FIGS. 1 through 4,or elevators 5 which are rigid parts of the rack in the secondembodiment variant according to FIGS. 7 through 10, and two horizontaltransport connections F1, F2, which are connected to the buffer stationsP1, P2, are rigid parts of the rack and are located on the same level inthe rack region, for feeding or removing containers 3 from or into atransport system or workplace (not shown), which is located outside therack system.

The transport connection F1 and F2, which is on the same level in theregion of the rack unit A, B, C, is led without crossing as a closedtransport loop directly to and from an individual workplace, especiallydirectly to and from an individual dispatch place of a dispatch unit,and containers dispatched from the rack 2 are transported on the saidtransport loop to the workplace and conversely, empty containers orpartially emptied containers 3 are transported from the workplace to therack 2.

A dedicated electronic control means for the storage and retrieval ofcontainers 3 is provided for each rack unit A, B and C.

As an alternative, a common electronic control means may also beprovided for at least a plurality of preferably adjacent rack units.

In both exemplary embodiments according to FIGS. 1 through 4 as well asaccording to FIGS. 7 through 10, the buffer zone P1, P2 and P3 hasstationary parking spaces 9 at the rack 2 at the level of each rack unitA, B, C for the interim storage of containers 3.

Furthermore, the buffer zone P1, P2 and P3 comprises, in both embodimentvarients, open linear horizontal conveyor tracks 8, likewise at thelevel of each rack unit A, B, C, on which containers 3 can likewise betransported and stored on an interim basis.

Finally, the buffer zone P1, P2 and P3 according to the secondembodiment variant according to FIGS. 7 through 10 comprise,furthermore, a preferably closed horizontal conveyor track 7 or aconveying loop arranged on the same level with a connection to anelevator 5, on which said track or loop containers can be transportedand stored on an interim basis and transferred to the elevator 8 ortaken over from the elevator 8. The containers 3 are fed and removedhere by means of the common elevator 5, contrary to the first embodimentvariant according to FIGS. 1 through 4, in which the containers 3 arefed and removed by means of elevators 6 a, 6 b.

Each rack unit A, B or C is accessible by means of a ladder.

The composite rack 2 may have rack units A, B, C, which have differentdesigns at least partially in terms of the depth of the rack, the heightof the rack and/or the container type supports. In particular, specialstorage means, especially flow racks, may be arranged in the rack unitsA, B, C.

Two-sided rack serving devices 4, which serve two rack halves each inthe corresponding rack aisle 14, are used in the composite rack 2comprising three double racks arranged one after another according tothe drawings. It is apparent that racks 2 may also be provided withinthe framework of the present invention in the form of parallelindividual racks located at spaced locations from one another andoptionally combined with double racks, in which case the individualracks can be served by rack serving devices located on one side, whichcan be displaced at the front of the rack. However, the racks 2 aredivided into independent rack units A, B, C in the vertical direction inall embodiment variants.

The first embodiment variant according to FIGS. 1 through 4 is operatedby means of rack serving devices 4 according to FIGS. 5 and 6 asfollows.

Product to be dispatched is dispatched manually in containers 3 at twoindividual dispatch places, not shown, which are connected to thetransport connections F1 and F2 without crossing.

Empty or partially emptied containers 3 (or full containers for fillingthe rack) enter the region of the linear conveyor track 8 connectedvertically to the elevator 6 a on the circulating transport connectionF1 and F2. The containers are transferred there onto the linear conveyortrack 8 by cross slides, not shown and undergo interim storage. Theelevator 6 a takes over a container located there and transports sameonto the level of a selected rack unit A, B or C, in which a freestorage site is present according to the computer control with pathoptimization. Once the level of the selected rack unit is reached, theelevator 6 a takes over the container 3 of the linear conveyor track 8located there, which leads to the stationary parking space 9 located onthe same level. The container is then ready on the parking space 9 forremoval by the rack serving device 4 of the corresponding rack unit A, Bor C on the front side of the rack 2. The actuated rack serving device 4moves to this parking space 9 and takes over the container 3 from thereonto the aligned elevating platform 11. The rack serving device 4 thenperforms an accelerated and decelerated movement horizontally and at thesame time vertically in the rack aisle 14 to the empty storage site ofthe rack unit A, B or C and fills the empty storage site with thecontainer 3.

A container 3 polled by the dispatch unit is retrieved from the rackessentially in the opposite direction. However, after leaving the rackserving device 4, the selected container 3 is brought on a separateconveyor track to the transport connection F1 and F2. The separateconveyor track is represented by the stationary parking space 9 and thelinear conveyor track 8, which are associated with the elevator 6 b. Adispatched container 3 transferred by this linear conveyor track 8 tothe transport connection F1 and F2 reaches the dispatch unit withoutcrossing.

Consequently, containers 3 are stored and retrieved on separate paths upto the rack serving device 4 according to the first embodiment variant.

The second embodiment variant according to FIGS. 7 through 10 isoperated by means of rack serving devices 4 according to FIGS. 5 and 6similarly to the operation of the first embodiment variant. However, acommon elevator 5 is used both for the storage and the retrieval ofcontainers 3, which has a correspondingly large platform and can pick upcontainers to be stored and retrieved at the same time. The elevator 5is integrated in each buffer zone P1, P3 or P3 in a closed circulating,horizontal conveyor track 7, on which containers 3 are fed and removed,as can be seen, on separate paths between the transport connection F1and F2 and the elevator 5.

While specific embodiments of the invention have been shown anddescribed in detail to illustrate the application of the principles ofthe invention, it will be understood that the invention may be embodiedotherwise without departing from such principles.

1. A method for operating a rack system with a rack and an associatedrack serving device for the storage and retrieval of objects to or fromthe rack, the method comprising: providing the rack divided into atleast two vertical rack regions arranged one above the other, with eachrack region comprising a plurality of adjacent rack planes arranged oneabove the other, wherein each rack region is an independent and closedrack unit each with a height-movable and length-movable rack servingdevice dedicated to each rack region and mechanically coupled to eachrack region; serving each rack region of the rack-with the respectiverack serving device by moving objects with the respective serving deviceto locations in the respective rack region and retrieving objects fromlocations in the respective rack region; transporting objects from or toa level of the respective rack region by at least one of an elevator andan at least partially horizontal transport connection that reaches onthe same level in the rack region of the rack unit from or to atransport system or workplace located outside the rack system; andstoring the objects on an interim basis in an interim storage in eachsaid rack region in a buffer zone arranged on the same level.
 2. Amethod in accordance with claim 1, wherein transporting includestransporting the objects via the transport connection without crossingto or from an individual workplace, or to or from an individual dispatchplace of a dispatch unit.
 3. A method in accordance with claim 1wherein, serving includes using a dedicated electronic control means foreach rack unit for the storage and retrieval of said objects.
 4. Amethod in accordance with claim 1, wherein serving includes using acommon electronic control means for a plurality of adjacent rack unitsfor the storage and retrieval of said objects.
 5. A method in accordancewith claim 1, wherein storing the objects includes transporting theobjects in one direction and storing the objects on an interim basis inthe buffer zone on a closed conveyor track in the buffer zone.
 6. Amethod in accordance with claim 1, wherein storing the objects includestransporting the objects and storing the objects on an interim basis inthe buffer zone on a open and linear conveyor track in the buffer zone.7. A method in accordance with claim 1, wherein storing the objectsincludes temporarily positioning the objects in stationary parkingspaces in the buffer zone.
 8. A method in accordance with claim 1,wherein said transporting objects from or to a level of the respectiverack region includes providing said at least one elevator as pluralseparate elevators and feeding and removing using said separateelevators.
 9. A rack serving system comprising: a rack divided into atleast two vertical rack regions arranged one above the other, with eachrack region comprising a plurality of adjacent rack planes each arrangedone above the other, wherein each said rack region is embodied as anindependent and closed rack unit; a dedicated, mechanically coupled,height-movable and length-movable rack serving device for each rackunit; a transfer station for each rack unit, the transfer station beinga rigid part of the rack; a buffer zone, said transfer station beingarranged on the same level with said buffer zone for said objects, inwhich said buffer zone objects are taken over for storage or arereleased from storage for retrieval; and a transport comprising at leastone of a transport connection that ends horizontally in the rack regionand an elevator, said transport being connected to the buffer zone andforming a rigid part of the rack for feeding or removing said objects toor from a transport system or workplace located outside the rack system.10. A rack serving system in accordance with claim 9, wherein saidtransport comprises the transport connection, which is arranged on thesame level in the region of the rack unit, is led without crossingdirectly to and from an individual workplace, as a closed circulatingconveyor track, on which containers dispatched from the rack aretransported to the workplace and conversely, said containers in an emptyor partially emptied state are transported from the workplace to therack.
 11. A rack serving system in accordance with claim 10, whereinsaid containers, are fed and removed by means of said separateelevators.
 12. A rack serving system in accordance with claim 10,wherein a common electronic control means is provided for at least aplurality of preferably adjacent rack units for the storage andretrieval of said containers.
 13. A rack serving system in accordancewith claim 9, wherein a dedicated electronic control means is providedfor each said rack unit for the storage and retrieval of said objects.14. A rack serving system in accordance with claim 9, wherein saidtransport comprises said elevator and the buffer zone has a closed andhorizontal conveyor track with a connection to said elevator, on whichsaid conveyor objects are conveyed in one direction and stored on aninterim basis and are transferred to the elevator or are taken over fromthe elevator.
 15. A rack serving system in accordance with claim 9,wherein the buffer zone has an open, linear, horizontal conveyor track,on which said containers , trays or the like are conveyed and undergointerim storage.
 16. A rack serving system in accordance with claim 9,wherein the buffer zone has stationary parking spaces at the rack forthe interim storage of said objects.
 17. A rack serving system inaccordance with claim 9, wherein each said rack unit is accessible bymeans of a ladder.
 18. A rack serving system in accordance with claim 9,wherein said rack units different as to at least one of depth of therack, height of the rack and type of object that can be moved and storedtherein.
 19. A rack serving system in accordance with claim 9, whereinthe rack has said rack units, in which special storage means includingflow racks, are arranged.
 20. A rack serving system in accordance withclaim 9, wherein the rack is composed of a number of parallel individualracks located at spaced locations from one another or double racks,wherein the individual racks are served from a front of the rack by saidrack serving devices located on one side and the double racks are servedin a rack aisle located between them by said two-sided rack servingdevices.
 21. A rack serving system in accordance with claim 9, whereinthe rack serving device has an elevating chassis and an elevatingplatform of a low overall height essentially at the same level, whereinthe elevating chassis and the elevating platform are arranged onopposite sides of a longitudinally displaceable elevator mast.
 22. Arack serving system in accordance with claim 21, wherein the elevatormast extends over the height of a rack unit and is guided at least atthe bottom in a longitudinal guide rail, which is an integral part ofthe rack.